Folded fastener products

Abstract

Fastener products having a multiplicity of fastener elements extending from a strip-form base, the base including first and second attachment members for attachment of a substrate therebetween, are formed by continuously introducing molten resin to a gap defined adjacent a peripheral surface of a rotating mold roll. The resin forms part of the strip-form base of the product at the peripheral mold roll surface and fills an array of fixed cavities defined in the rotating mold roll to form portions of the fastener elements as projections extending from a first side of the sheet-form base. While the resin is on the mold roll, a sheet material is introduced. The sheet material is folded about a longitudinal fold line to form first and second overlapping fold portions and is introduced under conditions selected to cause the second fold portion to become permanently bonded to resin of the base, while leaving the first fold portion remaining free to be subsequently unfolded from said second fold portion about said fold line. The resin is solidified and stripped from the peripheral surface of the mold roll by pulling the projections from their respective cavities. In some embodiments, a spring section is integrally molded with and extends laterally from a fastening section of the fastener product. The spring section is formed by at least one undulation of the sheet form base that allows the spring section to stretch elastically in a lateral direction upon application of lateral tension to the fastening assembly.

1 - 30 . (canceled)  
   
   
       31 . A method of forming fastener tabs, each tab comprising a multiplicity of fastener elements extending from a strip-form base and first and second attachment legs configured to attaching the tab to a garment or substrate placed between the legs, the method comprising: 
 continuously introducing molten resin to a gap defined adjacent a peripheral surface of a rotating mold roll, such that the resin forms at least a part of the strip-form base the peripheral mold roll surface and fills an array of cavities defined in the rotating mold roll to form portions of the fastener elements as projections extending from a first side of the strip-form base;    solidifying the resin;    stripping the solidified resin from the peripheral surface of the mold roll by pulling the projections from their respective cavities;    folding a portion of the strip-form base to form said first and second attachment legs; and    segmenting the strip-form base to define multiple fastener tabs.    
   
   
       32 - 75 . (canceled)  
   
   
       76 . The method of  claim 31 , further comprising, while 
 while continuously introducing the molten resin to the gap, introducing a pre-formed material to the resin under conditions selected to cause a portion of the resin to become permanently bonded to the pre-formed material, such that the preformed material also forms part of the strip-form base.    
   
   
       77 . The method of  claim 76 , wherein the folded portion of the strip-form base comprises at least a portion of the pre-formed material.  
   
   
       78 . The method of  claim 31 , wherein the folded portion of the strip-form base is folded about multiple fold lines separating more than two regions of the strip-form base.  
   
   
       79 . The method of  claim 31 , further comprising forming a non-planar undulation in which the base extends out of its plane to form a peak that extends along a longitudinal direction of said base with opposite major surfaces of the base remaining generally parallel, the undulation being elastically deformable to enable said base to stretch laterally upon application of a lateral tensile force.  
   
   
       80 . The method of  claim 79 , wherein non-planar undulation is molded in the gap.  
   
   
       81 . The method of  claim 79 , wherein the base has multiple, parallel undulations, each undulation forming a peak.  
   
   
       82 . The method of  claim 79 , wherein the undulation is pre-formed on a material that is introduced into the gap with the resin.  
   
   
       83 . The method of  claim 79  further comprising coating the undulation with an elastomer.  
   
   
       84 . The method of  claim 31  further comprising permanently joining two regions of the folded portion of the base to retain the base in its folded state.  
   
   
       85 . The method of  claim 84 , wherein the two regions of the folded portion are permanently joined by adhesive.  
   
   
       86 . The method of  claim 84 , wherein the two regions of the folded portion are permanently joined by ultrasonic bonding.  
   
   
       87 . The method of  claim 84 , wherein the two regions of the folded portion are permanently joined by heat staking.  
   
   
       88 . The method of  claim 31 , wherein folding the portion of the strip-form base comprises forming three longitudinal fold lines, with a middle one of the fold lines disposed between an inner fold line adjacent the projections and an outer fold line.  
   
   
       89 . The method of  claim 88 , wherein folding the portion of the strip-form base further comprises bringing the inner and outer fold lines together, to form the first attachment leg extending out of a plane formed by the strip-form base, with the middle fold line disposed at a distal end of the first attachment leg.  
   
   
       90 . The method of  claim 31 , wherein folding the portion of the strip-form base comprises forming two spaced-apart, longitudinal fold lines defining a middle base section therebetween, and overlapping the folded portion of the strip-form base to form a three-layer region of the base, with the middle base section between two other sections of the base.  
   
   
       91 . The method of  claim 31 , wherein the folded portion is folded along a hinge defined by a region of the base of decreased relative thickness.  
   
   
       92 . The method of  claim 31 , further comprising unfolding a fold of the folded portion to dispose the attachment legs in a flat, open position.  
   
   
       93 . The method of  claim 92 , further comprising applying an adhesive to an exposed surface of both attachment legs.  
   
   
       94 . The method of  claim 93 , further comprising placing a release liner over the adhesive on the attachment legs.  
   
   
       95 . The method of  claim 31 , wherein the projections, as molded, comprise functional fastener elements.